Method for forming three-dimensional support structure

ABSTRACT

A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation application of Ser. No. 13/487,107filed Jun. 1, 2012, now U.S. Pat. No. 8,585,565, which is a continuationapplication of Ser. No. 12/794,513 filed Jun. 4, 2010, now U.S. Pat. No.8,192,341, which is a continuation application of Ser. No. 11/459,550filed Jul. 24, 2006, now U.S. Pat. No. 7,762,938, the entire content ofeach of which is incorporated herein by this reference.

FIELD OF THE INVENTION

The present invention relates to structural products. More specifically,the present invention relates to three-dimensional support structures.

BACKGROUND OF THE INVENTION

Various sandwich-type structures currently exist that are used innumerous industries as components of products. These structures sufferfrom many drawbacks in strength, rigidity, weight, and durability.

For example, at the present time, structures for use in packagingtypically use corrugated board, to form, for example, corrugated boxes.Corrugated board is a sandwich of one or more liner sheets adhered to afluted, inner-medium. Combinations of liners and flute configurationsare used to generate variations of corrugated board. The weights ofmaterial used to form the liners and medium can be adjusted to achievedesired bursting and stacking strength. However, many disadvantages tocorrugated board exist. For example, corrugated board has a load bearingcapacity along only a single axis (the y-axis). Additionally, toincrease the width of the corrugated structure, yet retain structuralstability, a multi-wall corrugated board format is often used. Typicallya one, two, or three wall format corrugated board is used depending uponthe width needed. Delamination of attached liners adhered to the flutesis also a problem. Namely, the flutes comprise flexible contact pointsresulting in an uneven application of an adhesive between the flute andthe liner. Likewise, the uneven application and flexible contact pointscan lead to uneven surfaces for printing inks.

Corrugated board is also prone to warping during manufacture, which is aprominent issue within the industry. Moreover, the mechanical functionof corrugated board and the limitations of existing machinery (such ascorrugators) allow for only a narrow range of board types. Anotherdisadvantage of corrugated board is that its preparation requires theapplication of steam in order to form the curved flutes. The use ofsteam involves the consumption of water as well as the requirement tomanage the waste water within the corrugator system. Drying of the“steamed” corrugated board is also required. Drying of the steamedmedium paper occurs within the forming rolls that provide the fluteprofiles. These rolls are sometimes heated to approximately 700 F.° andin essence are pressing/ironing the fluted shape into the medium. As aresult additional energy, time, and expense is incurred in thepreparation of a product that is not very durable.

Various three-dimensional metal and plastic, and other compositematerial structures also exist. For example, structures, such asfuselages, wings, bulkheads, floor panels, construction panels,refrigerators, ceiling tiles, intermodal containers, and seismic wallsare often formed by corrugated metal or plastic sandwich structures orhexacomb products. Unfortunately, such structures have significantweight or mass associated with the structure, and typically involve amulti-piece core which requires welding or soldering, or other adhesivesfor assembly. Moreover, current metal and plastic structures often flexor curve along the x-axis, making it difficult to form a rigidstructure. These structures are also prone to create anticlasticcurvature. As a result, these structures are often costly, containnumerous components, do not have sufficient rigidity, and are oftenheavy.

In view of the foregoing, there is a need in the art for athree-dimensional support structure that will overcome the foregoingdeficiencies.

BRIEF SUMMARY OF THE INVENTION

An improved three-dimensional support structure is provided and includesa single sheet of material that is folded into a repeating pattern ofcells. Each of the cells is formed by first and second spaced-apartendwalls and first and second sloped sidewalls spanning between theendwalls. Each endwall comprises two plies of material while eachsidewall comprises a single ply of material. The first and secondsidewalls are adjoined at a folded edge. The cells are aligned such thatthe first endwall of one cell from the repeating pattern abuts thesecond endwall of an adjacent cell of the repeating pattern to form afour-ply wall of the material. A first liner may be attached to a firstside of the folded material and a second liner may be attached to asecond side of the folded material.

Other aspects, features and details of the present invention can be morecompletely understood by reference to the following detailed descriptionin conjunction with the drawings, and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example, with referenceto the attached drawings, of which:

FIG. 1 is a perspective view of a structure, partially cut away,incorporating the structure of the present invention.

FIG. 2 is a cross-sectional, perspective view, partially cut away, ofthe structure of FIG. 1 taken along the line 2-2 of FIG. 1.

FIG. 3 is a cross-sectional, perspective view, partially cut away, ofthe structure of FIG. 1 taken along the line 3-3 of FIG. 2.

FIG. 4 is a perspective view of the structure incorporated into thestructure of FIG. 1 taken along the line 4-4 of FIG. 1.

FIG. 5 is a perspective view of the structure incorporated into thestructure of FIG. 1 taken along the line 5-5 of FIG. 1.

FIG. 6 is a plan view of an unfolded sheet of material as creased toform the structure of FIG. 4.

FIG. 7 is a perspective view of the sheet of material of FIG. 6partially folded to form the structure of FIGS. 4 and 5.

FIG. 8 is a perspective view of a portion of the sheet of material ofFIG. 6 in its partially folded state.

FIG. 9 is a perspective view of a portion of the sheet of material ofFIG. 6 in a fully folded state to form a portion of the structure ofFIG. 4 shown by the dashed area 9-9 of FIG. 4.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is embodied in a three-dimensional supportstructure. As will be seen by the disclosure and drawings, the structureset forth herein is structurally superior to existing products, such ascontainer board, or corrugated board, and current sandwich-type metaland plastic structures. The structure set forth herein also requiresless material, and eliminates significant amounts of process energiescurrently required for manufacturing.

In a preferred embodiment, the three-dimensional support structure ofthe present invention is for use in the manufacture and composition ofpackaging materials and other support materials, including but notlimited to fuselages, wings, bulkheads, floor panels, constructionpanels, refrigerators, ceiling tiles, intermodal containers, and seismicwalls. However, it is appreciated that the structure disclosed hereinhas other applications where its advantages may be applied.

The three-dimensional support structure 10 disclosed herein comprises amedium or material 12 folded to form a durable structure. In a preferredembodiment, the tessellated medium 12 comprises flexible member,including but not limited to, paper, metal, plastic, composite, ormaterial of similar composition. The material may be of varying gradeand thickness, as is currently commercially available, and is based uponuser preferences.

FIG. 1 demonstrates a view of a material, the structure 10, of thepresent invention. The structure 10, in its fully assembled state,comprises a folded, tessellated medium 12 and optionally one or moreliners 14 attached thereto.

As can be seen from FIGS. 1-5, the structure 10 comprises a folded,tessellated medium 12 folded in multiple directions to form verticalstructures in three planar orientations, namely, the x-, the y- and thez-axis. Preferably, positioned and attached to the folded medium 12 isat least one liner 14. Preferably, the liner 14 is attached to a firstside or surface 16 of the folded medium 12. A liner 14 may also beattached to the second side or surface 18 of the folded medium 12.Preferably, a plurality of liners 14 are attached to the folded medium12. More preferably, the medium 12 is sandwiched between a pair ofliners 14. The liner 14 on the second surface 18 is positioned in aplane parallel to the liner 14 positioned on the first surface 16.Additional liners 14 may also be attached in various locations on thevarious planes and structures of the folded medium 12, depending uponthe user's desire, without departing from the overall scope of thepresent invention.

The liner 14 is made from any suitable material 17, such as a flexiblemembrane of paper, metal, plastic or composites, and may be of amaterial and form commonly available for the relevant application. Theliner 14 is preferably planar, and may be of any dimension. Preferably,the liner 14 corresponds in size to the width and length (the x- andy-axis) of the folded medium 12, but variations on the size of the liner14 do not depart from the overall scope of the present invention.

As discussed, the medium 12 is formed from a single sheet of material 19that is folded into a repeating pattern of cells 20 (see FIGS. 4 and 5).Each of the cells 20 is formed by, and comprises first 22 and second 24spaced-apart endwalls and first 26 and second 28 sloped sidewallsspanning between the endwalls. Each of the endwalls 22, 24 comprises twoplies of the material 12 and each of the sidewalls 26, 28 comprises asingle ply of the material 12. The first 26 and second 28 sidewalls areadjoined at a folded edge 30. The cells 20 are further aligned so thatthe first endwall 22 of one cell 20 from the repeating pattern abuts thesecond endwall 24 of an adjacent cell 20 from the repeating pattern toform a four-ply wall 32 of the material 12. Each of the repeating cells20 form opposite first 16 and second 18 surfaces having a recess orvalley 46 therein. Accordingly, the folded medium 12 forms one or morewall structures 32, or rails, for support of the liner 14, andpreferably forms a rigid support. The top 34 of the rails or four-plywall 32 as well as the top edges of 30 support the liner 14 thereon.

Each two-ply portion 36 of the material 12 of each of the first 22 andsecond 24 endwalls joins at a top fold 38. Two adjacent top folds 38comprise the top of the rail, or four-ply wall 32, that is part of thefirst surface 16 to which a liner 14 may be attached and part of thesecond surface 18 to which a liner 14 may be attached. In addition, thefirst surface 16 (and/or second surface 18) serves as a platform forsupporting an adhesive, or provides a surface for welding or soldering,that secures the liner 14 to the surface. Accordingly, the two adjacenttwo-ply folds 36 form part of a support rail 32, the top 34 of whichextends along the first surface 16 and along the second surface 18. Eachsubstantially continuous four-ply wall 32 is formed from a plurality oflongitudinally disposed, four-ply wall segments 40 (see FIGS. 4 and 9).As indicated, these four-ply wall segments 40 are formed by the foldingof the medium 12, resulting in the repeating pattern of cells 20, eachcell 20 formed in part by a two-ply wall segment 42, and a side wall 26,28 of each adjacent pair of cells 20 forming the four-ply wall segment40. The pattern results in the formation of at least one, but preferablya plurality of, parallel extending “double” ridges or rails 32 which arefour-plies thick from the folding of the single-ply medium 12. As can beseen in FIG. 4 and FIG. 5, the plurality of substantially continuousfour-ply walls 32 extend parallel to each other.

Each of the two-ply wall segments 42 is formed from material 12 having afold 44 extending longitudinally along the two-ply wall segment 42, asshown in FIG. 5. As can be seen from a comparison of FIGS. 6 and 7 withFIGS. 4 and 5, as the material folds at the two-ply wall folds 44, thesetwo-ply wall segments 42 are formed and further positioned adjacent toadditional two-ply wall segments 42 to form the cells 20 and four-plywall segments 40 described herein.

The pattern of repeating cells 20 forms a structure 10 having aplurality of columns, or four-ply walls 32, and recesses 46 formed fromthe plurality of cells. Namely, the single sheet of material 19 formsthe substantially continuous four-ply wall 32 of the material, describedabove, between each adjacent pair of columns and recesses. Each recessis formed, in part, by the spaced-apart four-ply wall segments 40.

In addition to the four-ply wall structure 32, the cells 20 formedcomprise a repeating pattern of ascending facets or sloped sidewalls 28and descending facets or sloped sidewalls 26 (see FIGS. 1-5). Thecombination of each adjacent ascending facet or sloped sidewall 28 anddescending facet or sloped sidewall 26 forms an apex, or peak 30, and avalley or recess 46. Specifically, a recess or valley 46 is formed byfacets 26 and 28 and a pair of adjacent four-ply wall segments 40 ortwo-ply wall segments 42. Likewise, the peak 30 is formed by facets 26,28 and at a peak fold 88. Adjoining facets 26 and 28 meet at the top ata ridge or peak 30, the peak fold 88, and at the bottom or base of thevalley 46, the valley fold 90. The peaks or ridges 30 and valleys 46 areperpendicular to the four-ply wall structure 32. Accordingly, thearchitecture of the folded medium 12 is comprised of a repeating patternof facets 26, 28 that are angled to follow a contoured path.

To form the structure 10 set forth in FIGS. 1-5, the material 12 must befolded from a substantially flat, planar state (see FIG. 6). Thetessellated medium 12 herein changes in three directions as it is foldedfrom its planar, unfolded state, as shown in FIG. 6, into the form shownin FIGS. 4 & 5. Specifically, the medium 12 increases in height (thez-axis), while decreasing in both length (the x-axis) and in width (they-axis).

In further detail, referring to FIG. 4, three structural planes of afolded tessellated medium 12 exist, including the x-axis, the y-axis andthe z-axis. Once the tessellated medium 12 folds into its designatedform, the vertical walls 32 extend in the y-axis. These walls are thefour-ply thick walls 32 that effectively create a continuous rail. Thisfour-ply structure 32, which is rigid, provides substantial strength tothe three-dimensional support structure 10. Specifically, a verticalfold 44 as provided, due to the four-ply wall structure, is not aflexible contact point and is thus quite strong. Preferably, a pluralityof rows of parallel ridges 34 formed by the top of the wall structure 32are created. As can be seen in FIGS. 4 and 5, these top 34 of rails 32exist on two of the two major surfaces 16, 18 of the folded material.Likewise, the medium 12, in its folded state, also comprises cells 20 ontwo major surfaces 16, 18 of the folded medium 12.

The folded medium 12 provides a unique platform for application of anadhesive, or for welding or soldering. Specifically, the rows offour-ply structures 32, 40 provide superior adhesion surfaces. Forexample, an adhesive, such as corn starch and other adhesives commonlyused for packaging structures currently commercially available, isapplied between the top portion 34 of the four-ply wall structure 32 andthe liner 14, and secures the liner 14 in position on the foldedtessellated medium 12. Likewise, the top portion 34 of the four-ply wallstructure 32 and the liner 14 may be welded, soldered, or otherwisefused together by means commonly used to attach two materials, such asplastic or metal, together. Namely, when the tessellated forms arefolded, the plurality of parallel ridges 34 that are created provideadhesion or welding or soldering surfaces. When adhesive is used, theadhesive is preferably applied to the apex of the folds 44 for attachingthe liner 14. Moreover, four-plies of material provide a platform forreceiving and retaining an adhesive, increasing, and preferablydoubling, the surface for adhesive application, thereby minimizingdelamination issues. The same location would also be used for welding orsoldering. Additionally, small pockets 48 are formed between theparallel two-ply rails 42 that make up the four-ply rail structure 34 tocapture additional adhesive.

The cells 20 on each of the two major surfaces 16, 18 of the medium 12also add certain advantages. For instance, when one or more liners 14are bonded to the surface or surfaces 16, 18, the cells 20 are closed,sealing air within each cell. As a result, these cells 20 providesuperior insulation qualities for thermal applications, such as may beused in the food industry or, for example, pizza boxes.

FIG. 6 shows a plan view of an unfolded tessellated medium 12, whichwhen folded, forms the structure of FIGS. 1-5. As indicated, the medium12 herein is folded, rather than curved. To accommodate same, creases orscores exist where the folding is to take place. The unfoldedtessellated medium 12 preferably contains a repeating pattern of scoresor creases that comprise the “fold lines” of the tessellated medium 12.In broad terms, the contour path for the tessellated medium is comprisedof a sheet of material 19 having a plurality of first crease paths 59,61 extending parallel to each other and a plurality of second creasepaths 60, 68 extending parallel to each other and intersecting the firstcrease paths 59, 61. Each first crease path 59, 61 is formed from aplurality of first path segments 63. Each second crease path 60, 68 isformed from a repeating pattern of first and second chevron legs 50, 52and a straight line or leg 56 extending from a free end 65 of one of thefirst and second chevron legs 50, 52. The two legs or lines of thechevron are equal in length and typically angled 120°. The straight lineextends from either line end. The third line may be of any length. Eachsecond crease path 60 is foldable in an opposite direction from theadjacent second crease path 68. This results in the formation of analternating pattern of ridges or peaks 30 and valleys 46 as the sheet ofmaterial 19 is folded. Each of the first crease paths 59, 61 arestraight lines extending between the ridges 30 and valleys 46 ofadjacent second crease paths 60, 68 to form a pattern of facets 80, 82,84 on the first surface 49 of the sheet of material 19. The sheet ofmaterial 19 is foldable along the first and second crease paths 59, 61,60, 68 to form a three dimensional support structure 10. The threedimensional support structure 10 extends in a plane, partially shown indotted lines in FIG. 5 and identified therein by letters A′-A″,characterized by a repeating pattern of normal walls, or end walls 22,24, formed by the facets 80, 82 between the chevron 50, 52 and inclinedwalls 26, 28 formed by the facets 84 between the straight lines or thirdlegs 56. The normal walls 22, 24 extend perpendicular to the planeA′-A″. The inclined walls 26, 28 are inclined relative to the planeA′-A″.

The normal walls 22, 24 comprise a wall 32 having four plies of thesheet of material 19. A liner 14 may be attached to the threedimensional support structure 10 at the top 34 of the four-ply wall 32.

The scoring pattern of the planar structure discussed above is explainedin further detail hereinbelow. For purposes of discussion only, the foldlines of the medium 12 will described as “legs”, however, anydesignation would be acceptable for the purposes provided.

Referring to FIGS. 6-9, in a preferred embodiment, the material 12comprises a first leg 50 and a second leg 52 forming the first chevron.The first leg 50 and second leg 52 are preferably of equivalent length.A first angle 54 exists between the first leg 50 and the second leg 52.The angle 54 preferably comprises an angle of 120°. A third leg 56extends from the second leg 52, and as shown in the Figures is of agreater length than the first and second legs, but may be of any lengthto accommodate manufacturing preferences. The third leg 56 extends fromthe second leg 52 at a second angle 58 of 150°. The series of first 50,second 52, and third 56 legs comprises the structure that forms arepeating pattern of the medium 12 described above.

The third leg 56 of the first pattern 60 60 a of the second crease path60 is connected to the first leg 50 of the adjacent or second pattern 62of the second crease path 60 along the y-axis, the third leg 56 of thesecond pattern 62 is connected to the first leg 50 of the adjacent orthird pattern 64 of the second crease path 60 along the y-axis, and soforth. A third angle 66, which is between the third leg 56 of the firstpattern 6060 a and the first leg 50 of the adjacent or second pattern62, comprises an angle of 150° opposite the second angle 58.

Connecting the repeating adjacent pattern of the second crease path 60to a parallel repeating pattern of the second crease path 68 in thex-axis is a plurality of additional legs. Namely, a fourth leg 70extends at a fourth angle 72 of 60° from the first leg 50 to connect thefirst leg 50 of the first pattern 60 a of the second crease path 60 witha corresponding first leg 50 of an adjacent parallel pattern 60 a of thesecond crease path 68 in the x-axis. A fifth leg 74 extends from theapex of the second angle 54 on the first pattern 60 a of the secondcrease path 60 to the apex of the second angle 54 of the adjacentparallel pattern 60 a of the second crease path 68 in the x-axis. Asixth leg 76 extends at a fifth angle 78 of 90° from the third leg 56 onthe first pattern 60 a of the second crease path 60 to the correspondingpoint on the third leg 56 of the adjacent parallel pattern 60 a of thesecond crease path 68 in the x-axis. As with the foregoing, thiscombination forms a repeating pattern.

The combination of these adjacent and parallel repeating patterns oflegs in the x- and y-axis, and their corresponding angles, form thearchitecture of the tessellated medium 12. Accordingly, as shown in FIG.8, the first leg 50 of the first pattern 60 60 a of the second creasepath 60 and the first leg 50 of a second, parallel pattern 60 a of thesecond crease path 68 in the x-axis are linked by the fourth leg 70 andthe fifth leg 74, defining a first facet 80. Likewise, the second leg 52of the first pattern 6060 a of the second crease path 60 and the secondleg 52 of the second, parallel pattern 60 a of the second crease path 68in the x-axis are linked by the fifth leg 74 and the sixth leg 76,defining a second facet 82. The third legs 56 of corresponding parallelpatterns 60 a of the second crease paths 60, 68 in the x-axis are linkedby the sixth leg 76 and a fourth leg 70 of an adjacent pattern 62,defining a third facet 84. These three facets 80, 82, 84 repeat in boththe y-axis (repeating in series as 80, 82, 84) and in the x-axis(repeating as the identical facet) (see FIG. 6).

Any number of repeating facets 80, 82, 84 may be used to form thematerial comprising the three-dimensional support structure 10.Preferably, the size of the three-dimensional support structure isdefined by the number of facets, the size of the facets, or the legscreating the facet, and the desired size of the structure to be createdby the folded tessellated medium.

As described, the scores, or legs, of the tessellated medium 12 serve toassist in folding the medium 12 into the structure shown in FIGS. 1-5.As the medium 12 is folded (see FIG. 7), the scores cooperate to form aseries of peaks 30 and valleys 46 in the medium 12 ultimately resultingin the repeating pattern of cells 20 described herein and shown in FIGS.3 & 4. For purposes of description herein, the folds that form peaks,generally, will be described as “peak” folds 88, while the folds thatform valleys, generally, will be described as “valley” folds 90.However, these designations are merely provided for purposes ofdescription herein, and other designations would be acceptable for thepurposes provided.

In each repeating pattern 60 a of the second crease path 60, the scoreline of the subsequent, adjacent parallel pattern 60 a of the secondcrease path 68 is oriented to fold in the opposite direction to thepattern 60 a of the second crease path 60. This results in analternating pattern of ridges or peaks 30 and valleys 46. As shown inFIG. 7, the score lines of the fourth leg 70, the fifth leg 74 and thesixth leg 76 form straight lines extending between the peak folds 88 ofthe ridges 30 and the valley folds 90 of the valleys 46 of the adjacentpatterns 60 a of the second crease paths 60, 68 to form a pattern offacets 80, 82, 84 on the first surface 49 of the medium 12. For example,the fourth leg 70 may be scored to form a valley fold 90. The fifth leg74 (which defines the second facet 82, as described above) is scored toform a peak fold 88. The sixth leg 76 (which defines the third facet 84,as described above), like the fourth leg 70, is the scored to form avalley fold 90. As a result, a peak or apex is created between thefacets 80, 82, 84. In the adjacent parallel pattern 60 a of the secondcrease path 68 to the first pattern 60 a of the second crease path 60along the x-axis, these score lines are oriented for folding in theopposite direction to those set forth in the previously describedpattern.

Similarly, the legs of sequential parallel patterns 60 a of the secondcrease paths 60 and 68, and in particular, each of the first 50, second52, and third 56 legs, in sequential patterns along the x-axis, areoppositely scored so that each leg 50, 52, 56 in the pattern of thesecond crease path 60 folds in a direction opposite to the identical legin the parallel pattern of the second crease path 68. In other words,with the exception of the outer edge 86 or end of the pattern, the firstleg 50 of the pattern 60 a of the second crease path 60 comprises avalley fold 90, while the first leg 50 of the pattern 60 a of the secondcrease path 68 comprises a peak fold 88. The first leg 50 of the pattern60 a of second crease path 92 forms a valley fold 90. As a result, apeak is created, the apex of which is the first leg 50 of the pattern 60a of second crease path 68. The first 50, second 52 and third 56 legs ofthe parallel pattern, along the y-axis, maintain the same foldorientation throughout the repeating pattern 60, 62, 64. Only the legsin the parallel patterns along the x-axis alternate in fold orientation.Thus, the repeating adjacent pattern of first 50, second 52, and third56 legs along the y-axis may all comprise an peak fold 88, oralternatively, may all comprise a valley fold 90 orientation.

In addition to the varying fold orientations, as the medium 12 isfolded, the first angle 54 narrows, resulting in slopes or facets 80, 82of increasing steepness. The fold may be continued until the first angle54 reaches approximately 0° (the angle being limited by the width of thematerial used). Upon reaching this approximately 0° angle, the faces ofthe first 80 and second 82 facets formed between a first repeatingpattern 60 a of the second crease path 60 and first repeating pattern 60a of the second crease path 68 are in substantial contact with oneanother (see FIG. 9). At the same time, the first 80 and second 82facets formed between the parallel pattern 60 a of the second creasepath 68 and parallel pattern 60 a of an additional crease path,identified by 92, in the x-axis fold to face away from one another. Thefirst 80 and second 82 facets of immediately parallel repeating patternsin the x-axis form the four-ply wall structure 32 described herein.Namely, the first facet 80 between first parallel patterns 60 a ofcrease paths 60 and 68 and the first facet 80 between first parallelpatterns 60 a of crease path 68 and crease path 92 form a first two-plywall segment 42, while the second facet 82 between first parallelpatterns 60 a of crease paths 60 and 68 and the second facet 82 betweenfirst parallel patterns 60 a of crease paths 68 and 92 form a secondtwo-ply wall segment 42. The first two-ply wall segment 42 is formed bya peak fold 88 of the medium 12 at the first leg 50. The second two-plywall segment 42 is formed by a peak fold 88 of the medium 12 at thesecond leg 52. The combination of the first two-ply wall segment 42 andthe second two-ply wall segment 42, in the folded state with the firstangle 54 at approximately 0° forms the four-ply wall segment 40.

As alluded to above, during folding of the medium 12, the angles betweenfacets on the crease paths 60, 68 of parallel repeating patterns 60 a,in the x-axis also change. Namely, as the material is folded, the angleincreases or decreases in degrees at the first leg 50, the second leg52, and the third leg 56. Referring to FIG. 7, the angle 94 defined atthe first leg 50 by the first facets 80 of the parallel patterns 60 a inthe x-axis (as well as the angle 96 defined at the second leg 52 by thesecond facets 82 of parallel patterns 60 a) changes from 180° (in themedium's completely unfolded state (FIG. 6)) to nearly 0° (in thecompletely folded state of the structure (FIG. 4)). The angle 94, 96 inthe folded state is limited only by the width of the medium 12. Theangle 98 defined at the third leg 56 by the third facets 84 of theparallel patterns 60 a changes from 180° (in a completely unfoldedstate) to an angle of approximately 60°. Based upon the alternationbetween the valley 90 and peak folds 88, this angle 98, likewise,alternates in orientation, resulting in a series of peaks 30 and valleys46. These peaks 30 and valleys 46 are positioned between parallelfour-ply wall structures 32.

While specific dimensions and patterns are set forth hereinabove, thedimensions and angles can be adjusted for specific applications withoutdeparting from the overall scope of the present invention. Moreover,examples of particular adjacent and/or parallel patterns have been givenherein. These examples may be applied to other locations on the medium12, such as a third or fourth of fifth pattern, and so forth. Likewise,orientations of the various patterns may be reversed from the specificdiscussion hereinabove without departing from the scope of the presentinvention.

The three-dimensional support structure of a preferred embodimentcomprises a medium 12 that is formed with a combination of folds ratherthan being shaped into flutes as, for example, is common with corrugatedboard. Furthermore, the medium 12 or material of the preferredembodiment comprises a tessellated medium 12 having an architecture thatallows the weights of liners 14 and medium 12 or material to be reducedwhile achieving the same, or better performance, than comparably ratedproducts. In addition, a weight reduction further results from adecrease in the volume of material used to prepare a structure, such asa package, or similar product, using the structure of the embodimentsdisclosed. For example, due to the unique architecture of thethree-dimensional support structure, applications involving a metalmedium 12, can be used to form a strong, rigid support structure evenwith extreme material thicknesses, such as a minimal thickness between0.125-0.25 inch, which greatly reduces weight and material costs, and isa significant advantage over currently available products. Thearchitecture of the multi-planar structure, as shown in FIGS. 4 & 5,created by the folding of the material or medium 12 allows the height ofthe folded structure 10, and thus the thickness, to be varied to adimension greater than that available in current products, such ascorrugated board, without loss of structural stability. The structure10, can be formed of any height, for example up to 1.5 inches, with asingle sheet while retaining the same structural stability. The heightis varied by altering the dimensions of the score lines. Preferably, athickness of up to 1.5 inches for specialty applications, such aspallets can be created from a single sheet of material. In comparison,corrugated board in a single wall format cannot exceed ¼inch in heightas it becomes structurally unstable. Furthermore, corrugated board'smaximum height of 0.5 inch can only be achieved with a triple-wallconfiguration.

Advantageously, the four-ply walls 32 of the three-dimensional structure10 prevent flexing a curvature along the x-axis. Likewise, thesefour-ply walls permit curvature along the y-axis without anticlasticcurvature in metal and plastic applications.

In addition to the capability described above, as a result of themulti-dimensional folded architecture, which creates significantstructural stability and firm or rigid contacts at the various rails 34,the three-dimensional support structure 10 comprises significantstrength and enhanced performance over currently available products, andpermits the use of lighter weight material for the medium 12. Forinstance, the structure 10 disclosed herein (FIG. 1) when used forpackaging, due to its rigid multi-planar structure, features ECT (EdgeCrush Test) performance both laterally and longitudinally. Bycomparison, corrugated board can perform in only a single dimension. Thedual ECT format of the three-dimensional support structure 10 results instronger container board boxes.

While the three-dimensional support structure 10 may be stronger thancurrently available products, additional strength can be added to thefolded structure. Specifically, the structure 10 disclosed herein can bevaried in strength by three different methods, namely, by changing thelength of the facets 80, 82, 84, by changing the medium thickness,and/or by altering the weight of the liner 14 and medium 12 materials.In comparison, the strength of products, such as plastic, metal, orcorrugated board can only be adjusted by varying the weight of the linerand medium. Moreover, the structure 10 disclosed, of a single wallformat (i.e. a liner-medium-liner format), can outperform double wallformats, such as corrugated board (i.e. liner-medium-liner-medium-linerformat). As a result, the structure of the preferred embodiment usesless material (or paper in a board-type structure) than traditionaldouble wall corrugated board. This reduction is also reflected inproduct weight loss, and in space saving for both storage and transport.

In addition, the grid platform (shown in FIGS. 4 & 5) created by thefolded medium 12 provides a foundation to support a printed substratefor boxes, such as a liner 14. The grid platform prevents the substratefrom becoming slack, as corrugated is prone to do because multiplecontact points exist.

Using the three-dimensional support structure described herein, a deviceor package may be formed. Specifically, a device or package or theircomponents may be formed having multiple walls, such as a box or adivider, wherein a plurality of structures 10 are integrally connectedto form a single package or device. The integral connection of aplurality of structures of the present invention may occur throughbonding, such as by adhesive or by other means, such as welding orsoldering. Likewise, a single sheet of the structure 10 may be foldedinto the desired shape.

Manufacturing the three-dimensional support structure 10 of thepreferred embodiment has several significant advantages over, forexample corrugated board. For instance, the structure does not requiresteam for purposes of shaping the medium because it is folded ratherthan shaped. Likewise, the structure does not need to be heated forpurposes of formation and drying. The structure does not comprisemultiple components that need to be adhered or welded together.Moreover, application of an adhesive, such as corn starch or otheradhesive substrate, can be completed at a reduced temperature.

Accordingly, the foregoing description and drawings disclose athree-dimensional support structure that achieves equal or greaterperformance to standard materials, with materials of lesser weights. Thestructure comprises a medium 12 that is folded to form a repeatingpattern of cells 20 and parallel four-ply rails 34, to which a liner 14is adhesively attached, welded, or soldered.

Although various representative embodiments of this invention have beendescribed above with a certain degree of particularity, those skilled inthe art could make numerous alterations to the disclosed embodimentswithout departing from the spirit or scope of the inventive subjectmatter set forth in the specification and claims. All directionalreferences (e.g., upper, lower, upward, downward, left, right, leftward,rightward, top, bottom, above, below, vertical, horizontal, clockwise,counterclockwise, x-axis, y-axis, and z-axis) are only used foridentification purposes to aid the reader's understanding of theembodiments of the present invention, and do not create limitations,particularly as to the position, orientation, or use of the inventionunless specifically set forth in the claims. Joinder references (e.g.,attached, coupled, connected) are to be construed broadly and mayinclude intermediate members between a connection of elements andrelative movement between elements. As such, joinder references do notnecessarily infer that two elements are directly connected and in fixedrelation to each other.

In some instances, components are descried with reference to “ends”having a particular characteristic and/or being connected with anotherpart. However, those skilled in the art will recognize that the presentinvention is not limited to components which terminate immediatelybeyond their points of connection with other parts. Thus, the term “end”should be interpreted broadly, in a manner that includes areas adjacent,rearward, forward of, or otherwise near the terminus of a particularelement, link, component, part, member. In methodologies directly orindirectly set forth herein, various steps and operations are describedin one possible order of operation, but those skilled in the art willrecognize that steps and operations may be rearranged, replaced, oreliminated without necessarily departing from the spirit and scope ofthe present invention. It is intended that all matter contained in theabove description or shown in the accompanying drawings shall beinterpreted as illustrative only and not limiting. Changes in detail orstructure may be made without departing from the spirit of the inventionas defined in the appended claims.

Although the present invention has been described with reference topreferred embodiments, persons skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

1-21. (canceled)
 22. A method for creating a three-dimensional supportstructure having opposite first and second surfaces, comprisingproviding a single sheet of foldable material having a first crease paththat is linear when the sheet of material is unfolded and a plurality offirst, second and third chevrons spaced apart along the first creasepath and extending parallel to each other when the sheet of material isunfolded wherein each chevron includes first and second chevron legsthat intersect each other at the first crease path and wherein the firstcrease path has a first path segment extending between the first chevronand the second chevron and a second path segment extending between thesecond chevron and the third chevron, folding the sheet of foldablematerial along the second chevron and along the second path segment in afirst direction and along the first path segment in a second directionopposite to the first direction so that each second chevron forms aridge disposed in the first surface of the support structure.
 23. Themethod of claim 22, further comprising compressing the sheet of foldablematerial so that each first chevron leg and second chevron leg movestowards the first crease path so as to form a four ply wall in the sheetof foldable material.
 24. The method of claim 22, wherein thecompressing step includes compressing the sheet of foldable material sothat the first and second chevron legs of each chevron extendsubstantially parallel to each other.
 25. The method of claim 24,wherein the compressing step includes compressing the sheet of foldablematerial so that the first and second chevron legs of each chevronextend substantially parallel to the first crease path.
 26. The methodof claim 22, wherein each of the first and second chevron legs of thesecond chevron has an end and wherein the sheet of foldable materialincludes a line segment extending from the end of each of the first andsecond chevron legs of the second chevron and wherein the folding stepincludes folding the sheet of foldable material along the line segmentsin the first direction so that the line segments form part of the ridgedisposed in the first surface of the support structure.
 27. The methodof claim 26, wherein each of the first and second chevron legs of thefirst and third chevrons has an end and wherein the sheet of foldablematerial includes a line segment extending from the end of each of thefirst and second chevron legs of the first and third chevrons andwherein the folding step includes folding the sheet of foldable materialalong the first and second chevron legs of the first and third chevronsand respective line segments in the second direction so that the firstand second chevron legs of the first and third chevrons and respectiveline segments form a ridge disposed in the second surface of the supportstructure.
 28. The method of claim 26, wherein the line segments arecollinear when the sheet of material is unfolded.
 29. The method ofclaim 22, wherein the first and second chevron legs of the secondchevron are equal in length.
 30. The method of claim 29, wherein thefirst and second chevron legs of the first and third chevrons are equalin length.
 31. The method of claim 22, wherein the first and secondchevron legs of the first, second and third chevrons are equal inlength.
 32. The method of claim 22, wherein each first chevron leg ofthe first, second and third second chevrons has an end and wherein thesheet of foldable material includes a first additional first crease pathextending between the ends of the first chevron legs and wherein eachsecond chevron leg of the first, second and third second chevrons has anend and wherein the sheet of foldable material includes a secondadditional first crease path extending between the ends of the secondchevron legs.
 33. The method of claim 32, wherein the first additionalfirst crease path and the second additional first crease path eachextend parallel to the first crease path when the sheet of material isunfolded.
 34. The method of claim 32, wherein the first additional firstcrease path and the second additional first crease path each includes anadditional first path segment extending between the first chevron andthe second chevron and an additional second path segment extendingbetween the second chevron and the third chevron, and wherein thefolding step includes folding the sheet of foldable material along eachadditional first path segment in the first direction and along eachadditional second path segment in the second direction.